Resin Joining Member Waterproof Connector Design

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Solution Overview

Problem

Existing connectors require multiple components and sealing members like O-rings for waterproofing, which increases manufacturing costs and limits design flexibility, and complicates assembly.

Innovation Solution

A connector design that integrates a housing, contact, and joining member formed from resin materials, where the joining member is closely fitted within a cylindrical shell, eliminating the need for O-rings and allowing for easy miniaturization and assembly, with the joining member providing adhesiveness when heat-treated to ensure waterproofing without a smooth inner surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sealing members such as O-rings are used for waterproofing, then waterproof capability is achieved, but the number of components increases and manufacturing cost increases

Engineering Contradiction:

Improvewaterproof capabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The joining member integrates multiple functions: it joins the housing to the contact, provides waterproofing by closely fitting within the shell's inner surface, and eliminates the need for separate sealing members. This merging of joining and sealing functions into a single component directly reduces the total number of components while maintaining waterproof capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The joining member serves multiple purposes simultaneously: structural joining, waterproof sealing, and space filling. By designing this single component to perform multiple functions that were previously handled by separate parts, the patent reduces component count and simplifies the overall structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If sealing members such as O-rings are used for waterproofing, then waterproof capability is achieved, but the number of assembly steps increases

Engineering Contradiction:

Improvewaterproof capabilityVSAvoidassembly steps

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The joining member combines the joining function and sealing function into a single component, allowing both operations to be performed in one assembly step. The housing and contact are joined while simultaneously achieving waterproofing, eliminating the need for separate sealing member installation steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The joining member is pre-formed with the capability to closely fit within the shell's inner surface, so that when the housing and contact are assembled, the waterproofing function is automatically achieved without requiring additional assembly operations for sealing.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If sealing members such as O-rings are used for waterproofing, then waterproof capability is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvewaterproof capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The joining member integrates joining and sealing functions, eliminating the need to manufacture and procure separate sealing members. This consolidation reduces material costs, manufacturing complexity, and overall production expenses while maintaining effective waterproofing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The joining member is formed from the same resin material as the housing, allowing both components to be manufactured using identical molding processes and materials. This homogeneity simplifies the supply chain, reduces material variety, and lowers manufacturing costs compared to using different materials for housing and sealing members.

Inventive Principle:

Principle #33Homogeneity

4Reliability

If sealing members are used for waterproofing, then waterproof capability is achieved, but design flexibility is limited due to the need for smooth surfaces

Engineering Contradiction:

Improvewaterproof capabilityVSAvoiddesign flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The joining member combines structural and sealing functions, allowing the shell's inner surface to serve dual purposes: structural support and waterproof sealing. This eliminates the requirement for smooth surfaces specifically for sealing, freeing up design flexibility for other functional considerations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The joining member's outer surface automatically provides the sealing function by closely fitting within the shell's inner surface, without requiring the shell's inner surface to have special smoothness properties. The joining member essentially creates its own sealing interface, independent of the shell's surface characteristics.

Inventive Principle:

Principle #25Self-service

5Reliability

If multiple components are used for connector assembly, then functional requirements are met, but miniaturization becomes difficult

Engineering Contradiction:

Improvefunctional performanceVSAvoidconnector size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The joining member merges joining and sealing functions into a single component, reducing the total number of parts and the space required for multiple components. This consolidation enables smaller overall connector dimensions while maintaining all necessary functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The joining member is nested within the shell, with its outer surface closely fitting the inner surface of the shell. This nested arrangement maximizes space utilization and allows for compact connector design, enabling miniaturization while preserving functional performance.

Inventive Principle:

Principle #7Nested doll (Nesting)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution reduces the number of components and assembly steps, lowers manufacturing costs, and enhances waterproofing capabilities while allowing for greater design flexibility and miniaturization without the need for O-rings or smooth inner surfaces.

Implementation Method 1

the resin material which forms the joining member has adhesiveness when the resin material is heat treated

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 2

the joining member is closely fitted within an inner surface of the shell

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10763611B2Connector with reduced components

Publication Date: 2020.09.01 JST MFG CO LTD

AI summary

The connector includes: at least one contact; a housing to which the contact is arranged; a shell formed into a cylindrical shape inside of which the housing is disposed; and a joining member formed of a resin material; wherein the housing and the contact form an integral unit by means of the joining member, and the joining member is closely fitted within an inner surface of the shell or the joining member is integrally coupled to the inner surface of the shell. Thus, the number of components of the connector can be reduced but the manufacturing flexibility thereof can be increased and the connector can be easily miniaturized and manufactured.